Corrugated fabric and method of making same



Nov. 21, 1961 G. D. MARTIN 3,009,232

CORRUGATED FABRIC AND METHOD OF MAKING SAME Filed April 23, 1958 INVENTOR. GER/41 0 0. M41977 WMM ATTORNEY United States' Patent O 3,009,232 CORRUGATED FABRIC AND METHOD OF MAKING SAME Gerald D. Martin, Valdosta, Ga, assignor to United States Rubber Company, New York, N.Y., a corporation of New Jersey Filed Apr. 23, 1958, Ser. No. 730,399 8 Claims. (Cl. 28-72) This invention relates to a novel textile fabric and a method of making the same.

In Foster Patent Re. 24,007 there are disclosed and claimed novel fabrics in which yarns that have a relatively high shrinkage when subjected to a given heat shrinking treatment are unidirectionally associated with yarns which do not shrink as much under the heat treatment. The former yarns are of such a nature and are so arranged with the less shrinkable yarns that when the former yarns shrink they buckle, or corrugate, the less shrinkable yarns, and they hold the less shrinkable yarns buckled thereafter. A plane resting on one surface of the fabric is spaced a substantial distance from a similar plane at its other surface. The less shrinkable yarns are of such a nature and are so arranged with transverse yarns interlaced therewith and with the other yarns in the fabric, that the fabric resiliently resists compressive forces to which it is subjected.

It is an object of this invention to provide a fabric of this type having a much greater resilience and rigidity than fabrics as constructed heretofore when made of the same yarns. The fabric in accordance with this invention may be thought of as including four plies, as the fabric of Re. 24,007, FIG. 2, may be thought of as including three plies, although the fabric is a unitary one produced in one weaving operation. In the fabric of FIG. 2 of Re. 24,007, there is an upper and a lower planar surface, or ply, formed by interlaced yarns. Intermediate these plies is the third ply disposed in undulations back and forth between the former two plies and having yarns interlaced at the crests of its undulations with yarns in the former two plies to tie the three plies into a unitary structure.

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water, and the heat shrinkable yarns are allowed to relax and contract, and the fabric is then cooled.

After shrinking, the less shrinkable yarns will extend in undulation between the places where they are interlaced with the first and second ply to space the first and second plies from each other, and the heat shrinkable synthetic yarns will maintain the undulated yarns in this condition.

The fabric may be considered a four ply fabric with a first and second ply formed by the heat shrinkable synthetic yarns, and having the third and fourth plies disposed between them in undulations in which the third and fourth plies hold the first and second ply spaced apart.

The fabrics in accordance with this invention have several desirable properties. First they are less compressible than fabrics made as theretofore, but utilizing the same yarns, and consequently they maintain their original thickness better under load. Secondly, they are more rigid and consequently they may be made in greater thicknesses, without introducing undesirable characteristics, than fabrics made as heretofore. Further, they resist racking, i.e., the tendency of one surface of the fabric to move in a direction lying in the plane of that surface while the other surface of the fabric remains stationary or moves in the opposite direction, under load. Thus, in general, the fabrics of this invention have a greater rigidity than fabrics made as heretofore; the advantages are especially important at greater fabric thicknesses, i.e., thicknesses of three-eights of an inch and larger.

For a better understanding of the nature of this invention, reference should be had to the following detailed description of specific embodiments thereof, when read in conjunction with the accompanying drawing forming a part of this specification, wherein:

FIG. 1 is a perspective view of a fabric is accordance with this invention;

FIG. 2 is a schematic end view of the fabric of FIG. 1, and

FIG. 3 is an enlarged view of a detail of FIG. 1.

Referring now to the drawing, a fabric in accordance with this invention is shown at 10 and cri,s

The fabric of this invention includes two plies formed by heat shrinkable synthetic yarns and interlaced transverse yarns, with the heat shrinkable synthetic yarns in both the first and second ply extending unidirectionally. For example, a woven fabric may include heat shrinkable synthetic warp yarns and interlaced transverse weft yarns. Extending unidirectionally with the heat shrinkable synthetic yarns are less shrinkable yarns interlaced with the transverse yarns of the first and second ply. These'less shrinkable yarns are divided into at least two groups; as the fabric is made one group is first interlaced with the ff' yarns of the first ply and thereafter, and spaced from this first interlacing, the yarns of theosecond group are interlaced with the yarns of the first ply. The yarns from v both plies interlace with the second ply, and theri again interlace with the first ply in spaced relation.

Where the less shrinkable yarns are interlaced with either the first or second ply, one or more transverse yarns interlace with both the heat shrinkable synthetic yarns and the less shrinkable yarns, and, of course, these transverse yarns also tie the several less shrinkable yarns, with which they interlace, together. Additionally, in a fabric in accordance with this invention, other transverse yarns interlace only with the less shrinkable yarns, in the two groups, intermediate the transverse yarns which tie the less shrinkable yarns to the first and second ply.

In accordance with the method of this invention, a fabric is woven as heretofore described. The fabric from the loom is subjected to heat, as by immersion in hot with this invention is shown at 10 and includes a first ply 11 including heat shrinkage synthetic yarns 12 and transverse yarns 13 interlaced therewith. A second ply 14 has heat shrinkable synthetic yarns 15 extending unidirectionally with yarns 12, and transverse yarns 16 interlaced with yarns 15.

Many heat shrinkable synthetic yarns having a relatively high shrinkage,and consequently being suitable for the yarns 12 and 15, are well known in the textile art. Examples of such yarns are: Branched polyethylene, as distinguished from the so-called linear polyethylene (an oriented polymerized ethylene); Rhovyl (polyvinylchloride); saran-the so-called high shrink type (a co- 7 polymer of vinyl chloride and vinylidene chloride); Verel II ('acrylonitrile copolymer), etc. In general the foregoing fibers will shrink 15% or more at temperatures at or below the boil (212 F.) and are eminently suitable for the relatively high shrink yarns. Other high shrink yarns are well known which will shrink an equivalent amount at higher temperatures, e.g. yarns formed of blends of branched and linear polyethylene.

Disposed between plies 11 and 14, are plies 17 and 18,- each of which includes yarns which are less shrinkable than the yarns 12 and '15 under the desired shrinking treatment, and which are designated 19, 19' respectively, and which extend unidirectionally with yarns 12 and 15. Yarns 19 are interlaced first with selected ones of transverse yarns 13, as along lines 20, and alternately with selected ones of transverse yarns 16, as along lines 21.

Similarly yarns 19' are interlaced first with selected ones of transverse yarns 13, as along lines 20' which is spaced from line 20, and alternately to selected ones of yarns 16, as along lines 21. It will be noted lines 20 lie between two lines 20 where yarns 19 are joined to the first ply. The manner of joining plies 17 and 18 to ply "14 is the same. Lines 20, 20' and 21, 21 of interlacings, each will comprise one or more transverse yarns 13, 16; for example two transverse yarns 13 may interlace with yarns 19 at each line 20.

Many yarns which shrink less than the heat shrinkable synthetic yarns 12, at a suitable shrinking treatment are well known to the textile art. For example if the heat shrinking treatment is to be a shrinkage in boiling water, and one of the yarns hereinabove mentioned which shrinks the requisite amount under this treatment is selected for the heat shrinkable synthetic yarns, the following fibers may be used for the less shrinkable yarns 19, 19': nylon (polyamide); saran-the so-called regular type; Dacron (an oriented polyester of terephthalic ester with ethylene glycol); etc.

Between plies 11, 14, additional transverse yarns 22, 22 interlace only with the less shrinkable yarns 19, 19' respectively. Many yarns are suitable for the transverse yarns 22, 22' and 13 and 15; for example, the less shrinkable fibers noted above are highly satisfactory.

It will be seen that plies 17, 18 intersect each other periodically along lines which have been designated 23 in the drawings. In one embodiment, at the lines 23, yarns 19 alternate with yarns 19 across the Width of the fabric, and the yarns 19, 19' lie closely adjacent each other, i.e., in abutting relation or spaced less than the diameter of a yarn 19 or 19' from each other along line 23.

The invention will be further illustrated by the following table which compares fabrics B, C, E and F, in accordance with this invention, with fabrics A and D, constructed with only three plies.

shrunk would resemble the fabric of FIGS. 1 and 2 but with the ply 17 removed. The plies 11, 14 and 18 of Example 1 would appear identical in number of yarns and yarn interlacing to similar plies in Example A, though of course Example A would not have the fourth ply interlaced with either of the other three plies.

Both fabrics were shrunk by controlled shrinkage 35% by immersing them in boiling Water at 210 F. while permitting them to shrink until they contracted the controlled amount.

Though these fabrics are quite similar, the difference in compressibility and thickness recovery indicated in the above table is remarkable. This is more so when it is noted that the initial thickness of Example B, the fabric in accordance with this invention was considerably over inch.

A comparison of Examples A and D shows the compressibility is decreased and the resilience increased by increasing the frequency of interlacing of the undulated ply with a shrinkable ply, but adding Example B to the comparison shows the improved rigidity and resilience obtained in accordance with this invention.

Examples C and F may be thought of as 5 ply fabrics, for they contained an additional planar ply generally parallel to plies 11 and 14, but passing through the lines 23 and interlaced with plies 17 and 18.

Because of the novel construction heretofore described, a fabric can be constructed in accordance with this in vention using more or heavier undulated yarns. The undulated yarns are divided into two groups; since the yarns are not adjacent each other save at the lines 23 more undulated yarns can be used in the fabric than in the fabrics constructed as heretofore. In general for a given thickness of fabric, the fabrics of this invention have a shorter distance between successive lines of interlacing of undulated yarns with the plies 11 or 14 than fabrics constructed as heretofore. Consequently fabrics 11, 14 are less likely to sag between the support lines 20, 20 etc.

Table I A B G D E F Examples Greige Shrunk Greige Shrunk Greige Shrunk Greige Shrunk Grcigc Shrunk Grcige Shrunk Each high shrink ply-yarns:

Material 12mil 12mil-- 1211111-- 1211111-- 12m1l-- 12m1l Warps/inch.. 2 18 22 22 22..... 24 7 24 27. First undulated ply-yarns:

Material 20 rnll Saran- 20 mil Saran- 20mi1-. Saran. 20mi1-. Saran. 12 miL. Saran. 12mi1 Saran warps/inch 18 22 18 22 22--.-. 18 22- 24 27.-. 24 27. Second undulated ply-yarns:

Material Sllflll. 2mil Saran Weits:

Material-' 12 mll Saran. Picks/inch [total] (divided equally among all the plies) 35 54 Thickness (inches):

No load warp Weifiilt (ounces/square yard) [theoreti- 12mil- Saran. 12n1ii-- Saran.

I Polyethylene. 9 All polyethylene branched" type monofilament. 3 All saran regular type monofilamcnt.

4 5 pound weight on a 2-inch diameter foot resting on a 2-inch diameter sample of fabric; load applied 5 minutes at time of measurement.

5 Load removed 1 minute at time 0i measurement.

The compressibility is arrived at by subtracting the loaded thickness from the no load thickness, and dividing the remainder by the no load thickness and multiplying by 100 to obtain the percent compressibility. The resilience is obtained by dividing the load removed by the no load figure and multiplying by 100 to obtain the percent resilience.

Example A, not in accordance with this invention, is constructed of the same yarns as is Example B which is Having thus described my invention what I claim and desire to protect by Letters Patents is:

1. A fabric comprising a first and second ply, each ply including heat shrunk synthetic yarns, and transverse yarns interlaced therewith, the heat shrunk synthetic yarns in the first ply extending unidirectionally with the heat shrunk synthetic yarns in the second ply, undulated yarns arranged unidirectionally with said heat shrunk synthetic yarns and extending back and forth between said plies,

in accordance with this invention. Example A when said undulated yarns being interlaced alternately with transverse yarns in said first ply and with transverse yarns in said second ply to tie the two plies and the undulated yarns into a unitary fabric, a first group of said undulated yarns being interlaced with transverse yarns in said first ply intermediate the transverse yarns in said first ply with which a second group of said undulated yarns are interlaced, and crossing yarns interlaced with said undulated yarns intermediate the first and second plies, said heat shrinkable synthetic yarns maintaining said undulated yarns undulated, and the undulations in said yarns spacing said first and second plies from each other.

2. A fabric comprising a first and second ply, each ply including heat shrunk synthetic yarns, and transverse yarns interlaced therewith, the heat shrunk synthetic yarns in the first ply extending unidirectionally with the heat shrunk synthetic yarns in the second ply, a third and fourth ply, each of said third and fourth plies being undulated and disposed between said first and second plies with the undulated yarns in said plies extending unidirectionally with said heat shrunk synthetic yarns, each of said undulated plies being interlaced periodically and alternately with said first and second plies to tie said four plies into a unitary fabric, said heat shrunk synthetic yarns maintaining said undulated yarns undulated, and the undulations in said yarns spacing said first and second plies from each other.

3. A fabric comp-rising a first and second ply, each ply including heat shrunk synthetic yarns, and transverse yarns interlaced therewith, the heat shrunk synthetic yarns in the first ply extending unidirectionally with the heat shrunk synthetic yarns in the second ply, a third and fourth ply, each of said third and fourth plies being undulated and disposed between said first and second plies with the undulated yarns in said plies extending unidirectionally with said heat shrunk synthetic yarns, each of said undulated plies being interlaced periodically and alternately with said first and second plies to tie said four plies into a unitary fabric, said third ply and said fourth ply passing through each other periodically intermediate said first and second plies, said heat shrunk synthetic yarns maintaining said undulated yarns undulated, and the undulations in said yarns spacing said first and said second plies from each other.

4. A fabric comprising a first and second ply, each ply including heat shrunk synthetic yarns, and transverse yarns interlaced therewith, the heat shrunk synthetic yarns in the first ply extending unidirectionally with the heat shrunk synthetic yarns in the second ply, a third and fourth ply, each of said third and fourth plies being undulated and disposed between said first and second plies with the undulated yarns in said plies extending in the same direction as said heat shrunk synthetic yarns, each of said undulated plies being interlaced alternately and periodically with said first and second plies to tie said four plies into a unitary fabric, said third ply and said fourth ply passing through each other periodically intermediate said first and second plies with said third ply interlacing with each of said first ply and said second ply at transverse yarns intermediate the transverse yarns at which the fourth ply interlaces with said first ply and with said second ply, said heat shrunk synthetic yarns maintaining said undulated yarns undulated, and the undulations in said yarns spacing said first and second plies from each other.

5. A fabric comprising a first and second ply, each ply including heat shrunk synthetic yarns, and transverse yarns interlaced therewith, the heat shrunk synthetic yarns in the first ply extending unidirectionally with the heat shrunk synthetic yarns in the second ply, undulated yarns arranged undirectionally with said heat shrunk synthetic yarns and extending back and forth between said plies, said undulated yarns being interlaced periodically and alternately with transverse yarns in said first ply and with transverse yarns in said second ply to tie the two plies and the undulated yarns into a unitary fabric, a first 6 group of said undulated yarns being interlaced with transverse yarns in said first ply intermediate the transverse yarns in said first ply with which a second group of said undulated yarns are interlaced, said first group of undulated yarns being interlaced with transverse yarns in said second ply intermediate the transverse yarns in said second ply with which the second group of undulated yarns are interlaced, said undulated yarns at the lines intermediate said first and second plies where the yarns in said first group intersect the plane formed by the yarns in said second group lying closely adjacent one another, and crossing yarns interlaced with each group of said imdulatcd yarns intermediate the first and second plies, said heat shrunk synthetic yarns maintaining said undulated yarns undulated, and the undulations in said yarns spacing said first and second plies from each other.

6. A fabric comprising a first and second ply, each ply including heat shrunk synthetic yarns, and transverse yarns interlaced therewith, the heat shrunk synthetic yarns in the first ply extending unidirectionally with the heat shrunk synthetic yarns in the second ply, undulated yarns arranged undirectionally with said heat shrunk synthetic yarns and extending back and forth between said plies, said undulated yarns being interlaced periodically and alternately with transverse yarns in said first ply and with transverse yarns in said second ply to tie the two plies and the undulated yarns into a unitary fabric, a first group of said undulated yarns being interlaced with transverse yarns in said first ply intermediate the transverse yarns in said first ply with which a second group of said undulated yarns are interlaced, said first group of undulated yarns being interlaced with transverse yarns in said second ply intermediate the transverse yarns in said second ply with which the second group of said undulated yarn are interlaced, said undulated yarns at the lines intermediate said first and second plies where the yarns in said first group intersect the plane formed by the yarns in said second group lying closely adjacent one another with a yarn from said first group alternating with the yarn from said second group along said lines, and crossing yarns interlaced with each group of said undulated yarns intermediate the first and second plies, said heat shrunk synthetic yarns maintaining said undulated yarns undulated, and the undulations in said yarns spacing said first and second plies from each other,

7. A method of producing a fabric which comprises weaving a fabric including a first and second ply, each ply of which includes heat shrinkable synthetic yarns and transverse yarns interlaced therewith, the heat shrinkable synthetic yarns in the first ply extending unidirectionally with the heat shrinkable synthetic yarns in the second ply, said fabric including yarns arranged unidirectionally with said heat shrinkable synthetic y'arns extending back and forth between said plies which shrink less than said heat shrinkable synthetic yarns and which are interlaced alternately with transverse yarns in said first ply and with transverse yarns in said second ply, a first group of said less shrinkable yarns being interlaced with transverse yarns in said first ply intermediate the transverse yarns in said first ply with which a second group of less shrinkable yarns are interlaced, said first group of less shrinkable yarns being interlaced with transverse yarns in said second ply' intermediate the transverse yarns in said second ply with which the second group of said less shrinkable yarns are interlaced, said fabric having crossing yarns interlaced with said less shrinkable yarns intermediate the places where they are interlaced with the first and second plies, heating said fabric to shrink the heat shrinkable synthetic yarns and to buckle the less shrinkable synthetic yarns into undulations between the first and second ply to space the first and second plies from each other, and cooling said fabric.

8. A fabric comprising a first and second ply, the yarns extending in one direction in each of said first and second plies being undulated, a third ply including heat 7 shrunk synthetic yarns and transverse yarns interlaced therewith, the heat shrunk sy'nthetic yarns in the third ply extending unidirectionally with the undulated yarns in the first and second plies, each of said undulated plies being interlaced with said third ply to tie said three plies into a unitary fabric, said first ply and said second ply passing through each other periodically, said heat shrunk synthetic yarns maintaining said undulated yarns undulated, and the undulations in said yarns being such that 8 a plane tangent to the crest of the undulations on one side of said fabric is spaced from a plane tangent to the crest of the undulations on the other side of said fabric.

Foster May 24, 1955 French Aug. 26, 1941 

7. A METHOD OF PRODUCING A FABRIC WHICH COMPRISES WEAVING A FABRIC INCLUDING A FIRST AND SECOND PLY, EACH PLY OF WHICH INCLUDES HEAT SHRINKABLE SYNTHETIC YARNS AND TRANSVERSE YARNS INTERLACED THEREWITH, THE HEAT SHRINKABLE SYNTHETIC YARNS IN THE FIRST PLY EXTENDING UNIDIRECTIONALLY WITH THE HEAT SHRINKABLE SYNTHETIC YARNS IN THE SECOND PLY, SAID FABRIC INCLUDING YARNS ARRANED UNDIRECTIONALLY WITH SAID HEAT SHRINKABLE SYNTHETIC YARNS EXTENDING BACK AND FORTH BETWEEN SAID PLIES WHICH SHRINK LESS THAN SAID HEAT SHRINKABLE SYNTHETIC YARNS AND WHICH ARE INTERLACED ALTERNATELY WITH TRANSVERSE YARNS IN SAID FIRST PLY AND WITH TRANSVERSE YARNS IN SAID SECOND PLY, A FIRST GROUP OF SAID LESS SHRINKABLE YARNS BEING INTERLACED WITH TRANSVERSE YARNS IN SAID FIRST PLY INTERMEDIATE THE TRANSVERSE YARNS IN SAID FIRST PLY WITH WHICH A SECOND GROUP OF LESS SHRINKABLE YARNS BEING INTERLACED WITH TRANSVERSE YARNS IN SAID SECOND PLY INTERMEDIATE THE TRANSVERSE YARNS IN SAID SECOND PLY WITH WHICH THE SECOND GROUP OF SAID LESS SHRINKABLE YARNS ARE INTERLACED, SAID FABRIC HAVING CROSSING YARNS INTERLACED WITH SAID LESS SHRINKABLE YARNS INTERMEDIATE THE PLACES WHERE THEY ARE INTERLACED WITH THE FIRST AND SECOND PLIES, HEATING SAID FABRIC TO SHRINK THE HEAT SHRINKABLE SYNTHETIC YARNS AND TO BUCKLE THE LESS SHRINKABLE SYNTHETIC YARNS INTO UNDULATIONS BETWEEN THE FIRST AND SECOND PLY TO SPACE THE FIRST AND SECOND PLIES FROM EACH OTHER, AND COOLING SAID FABRIC. 